Quilting Machine Thread Adjuster for Unthreading Prevention
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Solution Overview
Problem
High-speed quilting machines face issues with thread management, where cutting threads between patterns can lead to unthreading of needles or loopers, resulting in machine shutdowns or defective quilts due to insufficient or excessive thread length, causing missed stitches.
Innovation Solution
A quilting machine with an adjuster mechanism that captures and pulls a predetermined amount of thread from the looper, ensuring sufficient length to prevent unthreading while minimizing excess thread, and a computer program product to control the thread cutting and repositioning process, allowing for seamless pattern changes without manual trimming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the thread is cut after the previous pattern has been stitched to avoid loose threads, then the quilt appearance is improved, but the needle or looper may become unthreaded requiring machine shutdown
Solution Approach 1:
The system performs preliminary action by pulling a predetermined amount of thread from the looper before cutting the thread. This ensures sufficient thread length remains in the looper to prevent unthreading while still allowing the thread to be cut for a clean appearance. The thread is prepared in advance with the correct length to maintain continuity after cutting.
Solution Approach 2:
The system changes the parameter of thread length by pulling a predetermined amount of thread from the looper before cutting. This parameter adjustment ensures the thread is long enough to prevent unthreading but not so long as to create excessive tails, resolving the contradiction between clean appearance and thread continuity.
2Reliability
If the thread length is increased to prevent unthreading, then the reliability is improved, but the quilt requires manual trimming due to excessive thread tails
Solution Approach 1:
The system precisely controls the thread length parameter by pulling a predetermined amount of thread from the looper. This ensures the thread is long enough to prevent unthreading (improving reliability) but not excessively long to create problematic tails (reducing harmful factors). The predetermined amount optimizes both aspects simultaneously.
Solution Approach 2:
The system makes the thread management self-service by automatically pulling the predetermined amount of thread and positioning it for cutting. This automated process ensures consistent thread length without manual intervention, preventing both unthreading and excessive tails while eliminating the need for manual trimming.
3Object-generated harmful factors
If the thread is cut to prevent excessive tails, then the quilt appearance is improved, but the needle or looper may become unthreaded
Solution Approach 1:
The system performs preliminary action by pulling a predetermined amount of thread from the looper before cutting. This ensures sufficient thread length remains in the looper to prevent unthreading while still allowing the thread to be cut for a clean appearance. The thread is prepared in advance with the correct length to maintain continuity after cutting.
4Object-generated harmful factors
If manual trimming is performed to remove thread tails, then the quilt appearance is improved, but the productivity decreases due to additional processing time
Solution Approach 1:
The system makes the thread management self-service by automatically pulling the predetermined amount of thread and positioning it for cutting. This automated process ensures consistent thread length without manual intervention, preventing both unthreading and excessive tails while eliminating the need for manual trimming.
Solution Approach 2:
The system replaces manual trimming with an automated mechanical system that pulls and cuts the thread at the predetermined length. This substitution eliminates the need for manual intervention, maintaining quilt appearance while preserving productivity by integrating thread management into the automated quilting process.
Data Source
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AI summary
Apparatuses, methods, and computer program products for quilting webs. A quilting machine (10) includes a cutting edge (256), a looper (76) from which thread (202) is provided to form stitches, and an adjuster assembly (88) that includes a plurality of selectable positions. The adjuster assembly (88) extends an adjuster (210) toward the thread (202) between the looper (76) and the retainer (90). When the adjuster (210) is moved, a predetermined amount of thread (202) is pulled away from the looper (76) by the adjuster (210) to provide a controlled length of thread (202) between the looper (76) and the cutting edge (256). The adjuster (210) is configured to be moved to an intermediate selectable position prior to starting a quilting pattern, and from the intermediate position to another selectable position subsequent to starting the quilting pattern.